A Comparison Study of 3D Scanners for Diagnosing Deviations in Their Outputs Using Reverse Engineering Technique

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1 IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-issn: ,p-ISSN: X, Volume 14, Issue 3 Ver. I (May. - June. 2017), PP A Comparison Study of 3D Scanners for Diagnosing Deviations in Their Outputs Using Reverse Engineering Technique Sreeram Reddy Gundeti 1, Rehal Burukani 2, Manzoor Hussain 3 ( 1,2 Department of Mechanical Engineering, VidyaJyothi Institute Of Technology,Hyderabad, T.S., India.) ( 3 Department of Mechanical Engineering,JNTUH College Of Engineering,Hyderabad,T.S., India) Abstract:These days in the field of engineering several types of 3-D scanners such as laser or optical 3D scanners are used for object digitalization.in this work comparing two types of 3-D non- contact type scanners that is V5 perceptron 3D laser scanner and 3D SYSTEMS CAPTURE SCANNER(fast blue light 3D scanning technology).the physical object is scanned individually for obtaining point cloud data of a existing freeform surface through these two scanners.the obtained data through scanning is then generated into ASCII(.asc file )file format type.so eventually both scanned files are evaluated through concerned reverse engineering software with necessary modules.in this standard deviation, Deviation status and deviation distribution are evaluated by comparing the reverse engineering model with the original CAD model over the free form surface. Keywords: 3D scanners, point data, free form surface,non-contact scanners, scanning comparison I. Introduction The device which converts 3 dimensional physical data into digital data is known as 3D scanners. During this scanning process these scanners collects the data or information of shape and dimension of physical object. So the points which are made up through scanning is called as point cloud data such that each individual scanned point has a particular position in the 3 dimensional space in the coordinate system. In similar way reverse engineering can be stated as duplication of already existing part by collecting the data or information such as shape and dimension of the object. This process is generally referred as reverse process to the conventional engineering process There will be a certain sequence followed in the process of reverse engineering such as [9] DATA CAPTURE PRE PROCESSING SEGMENTATION & SURFACE FITTING CAD MODELCREATION These 3D scanners can be divided into two types based on their physical parameter they are: [3] I. Contact type: In this scanner should be in physical contact with the object. II. Non contact type: In this there is no physical contact between the scanners and object.they can scan the data without any mechanical contact with the object [1] Based on scanning acquisition 3D scanners can be further divided into [3] Optical scanning method: In this object is scanned through several angles based on photographic principle and all the scans are subsequently accumulated to form a single digitized 3D image Laser scanning method: This works on the principle of laser triangulation.in this data is obtained to light reflection method based on its time period [1] Ultrasonic scanning method: In this method ultrasonic waves are subjected to the object through certain angles Mechanical type: This can be done through measuring arms and CMM machines in this entire information of the surface is not obtained but through selection of points locality of points can be obtained Destructive type: In this scanner breaks the object in order to get the interior and exterior data of the object. Based on their varied ranges scanners can be classified as: SHORT RANGE 3D SCANNER [8] :- Short Range 3D scanners generally utilize a Laser triangulation or Structured Light technology. In this they generally use white LED light or blue light phenomena during data acquisition. This type of short range 3D scanner has its own benefits such as o Less sensitive to changing light conditions and ambient light o Able to scan tough surfaces, such as dark and shiny surface finishes o This are very much portable o It is available at low cost o Eye safe for 3D scanning of humans and animals DOI: / Page

MEDIUM AND LONG RANGE SCANNER [8] :- Long range 3D scanners come in two major formats - Pulse based and phase shift both of which are well suited for large objects such as buildings, structures,

These scanners capture millions of points by rotating 360 degrees while spinning a mirror the redirects the laser outward towards the object or areas to be 3D scanned.

2 MEDIUM AND LONG RANGE SCANNER [8] :- Long range 3D scanners come in two major formats - Pulse based and phase shift both of which are well suited for large objects such as buildings, structures, aircraft, and military vehicles. Phase shift 3D scanners also work well for medium range scan needs such as automobiles, large pumps and industrial equipment. These scanners capture millions of points by rotating 360 degrees while spinning a mirror the redirects the laser outward towards the object or areas to be 3D scanned. Some of its benefits are o 3D scan million of data points in a single scan o It can scan upto area 1000 meters o Good accuracy and resolution based on object size o Non- contact type and keeps the object safe II. Scanners 2.1 V5 PERCEPTRON 3D LASER SCANNER: This scanner uses twin camera technology such that we can see two sides of an object at one instance this scanner produces high quality data acquisition and high dynamic range for scanning with high resolution of points along the laser line over the object. [5] This V5 sensor has the ability to scan data on dark and reflective surfaces and projects an accurate trapezoidal representation of the field, this enables the user to become familiar with good scanning practices and minimizing overlapping data. This is suitable for various industries and applications, from the factorfloor to inspection rooms and laboratories. Specifications of v5 perceptron 3D laser scanner Figure 1:v5 perceptron 3D laser scanner 2.2.3D SYSTEMS CAPTURE SCANNER: The 3D system capture scanners provide accurate and fast blue light 3d scanning technology. These scanners are generally portable and can be handled easily. The main advantage of this scanner is it is easy to access multiple scanner configuration.lost data of 3D CAD model for highly complex and broken parts of the model can be easily recreated[6]. Specifications of 3D systems capture scanner: DOI: / Page

Figure 2:3D systems capture 3D scanner III.

acquiring and comparing of efficiency of

reference to the original CAD model to RE

3 Figure 2:3D systems capture 3D scanner III. Methodology: The steps involved in the data acquiring and comparing of efficiency of scanner based on their deviations with reference to the original CAD model to RE model are as follows: Figure 3:physical free form surface model 3.1 Data acquiring and comparing DOI: / Page

4 IV. Experimental Work In this article of reverse engineering the point data of physical freeform surface is acquired by using two non-contact type scanner which is V5 perceptron 3D laser scan based on twin camera technology and the other scanner is 3D systems capture scanner based on capture technology trough different angles with fast blue light falls on the freeform surface of physical model. A component is selected for the testing in such a way that it satisfies scanning criteria which has a complex freeform shape for scanning in order to know accuracy. Number of data points varies with each and every individual scanners in this case V5 laser perceptron 3D scanner has obtained data points, whereas for 3D systems capture 3D scanner has data point for the free form surface of the physical object. After certain multiple scans w.r.t angles the obtained data points are converted into ASII (.asc) file format based on the convenience required for CAD software package.this all collective data s of point cloud are imported into GEOMAGIC software. In this software we reconstruct the 3D free form surface this eventually gives us the RE based model [4]. then this RE based model and original CAD model is compared to obtain deviation.before the final deviations are obtained certain process should be followed in comparison of CAD model and RE model such as noise reduction, sampling,meshwrapping defect, surface smoothing, model simplification, holes filling on model Then next step in the process will be locating the model in the co-ordinate system with reference to the x, y, z plane. This can be done by both the test and reference object such that test object should be reoriented in such a way that three planes should match the reference objects. For final deviations of the models can be understand through the color coded mapping of difference between the selected objects. from this we get both the standard deviations and average deviations values through reference points.at last the outputs/deviations are compared between the both v5 perceptron and capture scanner and we conclude the better scanning performance. V. Results AND DISCUSSION: We need to consider the deviations in the shape, dimensions and orientation deviations as evaluating characteristics.by keeping tolerance as 0.5mm we should compare the RE model with CAD model for individual scanners V5 PERCEPTRON 3D SCANNER Comparison of deviation distribution 3D SYSTEMS CAPTURE 3D SCANNER >=Min <Max # Points % >=Min <Max # Points % Out of Upper Critical 1 Out of upper critical 0 Out of Lower Critical 0 Out of lower critcal 0 DOI: / Page

Figure 4: v5 perceptron deviation distributionfigure 5: capture scanner deviation distribution Comparison of standard deviation V5 PERCEPTRON 3D LASER SCANNER 3D SYSTEMS CAPTURE 3D SCANNER

7-3* std. Dev. 1630 1.2105-3*std. Dev. 6719 3.36-2* std. Dev. 14239 10.5746-2*std. Dev. 19009 9.5121-1* std. Dev. 58378 43.3544-1*std. Dev. 63452 31.7514 1* std. Dev. 39310 29.1936 1*std. Dev. 80992 40.

Dev. 293 0.2176 6*std. Dev. 0 0 Fig 6: v5 perceptron std* dev Fig 7: capture 3D scanner std* dev LOCATION SET: PERCEPTRON CAPTURE 3D Name Upper Tol Lower Tol Ref. X Ref. Y Ref. Z Dev. Status Dev.

5 Figure 4: v5 perceptron deviation distributionfigure 5: capture scanner deviation distribution Comparison of standard deviation V5 PERCEPTRON 3D LASER SCANNER 3D SYSTEMS CAPTURE 3D SCANNER Distribution(+/-) Points Percentage% Distribution(+/-) Points Percentage% -6*std. Dev *std. Dev *std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev * std. Dev *std. Dev. 0 0 Fig 6: v5 perceptron std* dev Fig 7: capture 3D scanner std* dev LOCATION SET: PERCEPTRON CAPTURE 3D Name Upper Tol Lower Tol Ref. X Ref. Y Ref. Z Dev. Status Dev. Status L PASS PASS L PASS PASS L PASS PASS L PASS PASS L PASS PASS L PASS FAIL L PASS FAIL L PASS FAIL L PASS FAIL L PASS PASS L PASS PASS L PASS FAIL L PASS PASS L PASS FAIL DOI: / Page

L15 0.1372-0.1372-27.43 24.4948 54.8729 0.0094 PASS 0.0957 PASS L16 0.1372-0.1372-27.43 20.8606 82.3094 0.011 PASS 0.1444 FAIL L17 0.1372-0.1372-27.43 24.6770 27.4365-0.0085 PASS 0.0521 PASS L18 0.

This table shows that the perceptron 3D scanner resulted with all PASS points which resembles that it has very minute variation in their deviation individually.

6 L PASS PASS L PASS FAIL L PASS PASS L PASS PASS In this all the 18 predefined points are compared giving out the deviation status as PASS or FAIL points. This table shows that the perceptron 3D scanner resulted with all PASS points which resembles that it has very minute variation in their deviation individually. While the 3D systems capture 3D have some failure points at location set i.e, L6,L7,L8,L9,L12,L14,L16. This states that capture have very large deviations in their freeform surface point data in the process of comparing RE model with the original CAD mode Pictorial representation of deviations: Figure 8:v5 perceptron Figure 9:capture 3D scanner VI. Conclusion In this evaluation is done over the complex freeform surface with deep curved profiles are considered. The above comparative study of outputs illustrates that Laser scanner have great accuracy when compared to capture scanner i.e., V5 Perceptron (twin camera technology) scanner has better accuracies when compared with 3D systems capture 3Dscanner. In this comparison V5 perceptron has very minimal variation, by having minimum percentage of points in the range of to in Deviation distribution,58378 points in -1* standard dev. Distribution points in 1* standard. This values are far better when compared with the 3D system capture scannerwith the reference of all 18 location set (L1-L18). This concludes that V5 perceptron 3D scanner is fast and better at scanning the complex freeform surface than that of capture 3D scanner.all the deviation values are depicted in the table 1,2,3 shows the accuracies of both the scanner.which directly emphasizes that the value with lower deviation has high accuracies and better scanning performance. From the above experiment we can observe that v5 perceptron scanner better comparatively. References [1] G. Sreeram Reddy *, ManzoorHussain, J. Jagadesh Kumar and V.V.Satyanarayana, Experimental Investigation on Reverse Engineering of a Typical Freeform Surface using Portable Laser Arm Scanner, 05 Sept 2016, Vol.6, No.5 (Oct 2016). [2] TeodorTóth*, JozefŽivčák, A Comparison of the Outputs of 3D Scanners, Procedia Engineering 69 (2014) [3] Ngozi Sherry Ali, Reverse Engineering of Automotive Parts Applying Laser Scanning and Structured Light Techniques, MAY [4] Claus-Peter Alberts, Surface reconstruction from scan paths, Future Generation Computer Systems 20 (2004) [5] [6] [7] Christopher j. rolls, CAD model construction from CMM and laser scanning data for reverse engineering [8] [9] Varady, T.Martin, Reverse engineering of geometric models-an introduction, computer aided design, v.29, 1997, pp [10] Mr. S. P. Sathya Prasanth1 DR. V. Dhanalakshmi2, Comparison of Data Capturing Techniques and Analysis of Part Model in Reverse Engineering [11] Spencer Onuh, Nick Bennett, and Jim Baker, Rapid Prototyping: Practical Approach to Enabling Reverse Engineering, Proceedings of SPIE, DOI: / Page

7 [12] Sreeram Reddy Gundeti, Sree Krishna Guthena, RehalBurukani, SaiTejaKanaparthy. THE COMPARATIVE ANALYSIS OF DEVIATIONS WITH DIFFERENT NON-CONTACT SCANNERS OF A FREEFORM SURFACE USING REVERSE ENGINEERING APPROACH. Proceedings of International Conference on Frontiers in Engineering, Applied sciences and Technology; ISBN: , Vol. 3, March 31 st & April 1 st, [13] Sreeram Reddy Gundeti, Sree Krishna Guthena. The comparison of deviations of freeform surfaces using re-engineering by noncontact scanners. International Journal of Mechanical and Production Engineering Research and Development (IJMPERD), ISSN(P): ; ISSN(E): , Vol. 7, Issue 2, Apr 2017, DOI: / Page

Indian Journal of Engineering

Indian ANALYSIS Journal of Engineering, Vol. 14, No. 36, April-June, 2017 ANALYSIS ISSN 2319 7757 EISSN 2319 7765 Indian Journal of Engineering The deviation analysis-comparison between two non contact